One-piece upper shell of a die-cast rear axle beam

Winner Aluminium

Dimension (L x W x H): 1.260 mm x 670 mm x 390 mm

Weight: 19.300 gram

Alloy: Al Si 10MnMg

High functional integration with connection points for the mounting of control arms, struts and stabilizers, the electric drive unit and for fastening the parts composite to the vehicle body.
Worthy of particular mention is the creation of a closed cavity by means of a hollow profile integrated into the casting process which, in conjunction with the topology-optimized design of the upper shell, meets all strength, stiffness and NVH requirements in the die casting process. The integral design of the TOP-HAT avoids complex joining processes and eliminates various individual components.

Design, casting and molding requirements:
In the casting and mold design of the 36to DGF with a contour slide, supported by various simulation software, the focus was on the following features: optimum filling over the entire component and in part local compaction of the critical functional areas, optimum vacuum-assisted venting of the cavity, material reductions of thick-walled areas taking into account the strength requirements, optimization of the processing contents and contours, use of special mold technology such as JetCooling integrated in the squeezing area and the fixing of a long cavity-generating insert to improve the NVH behavior.
The basis for this was provided in advance by: design space investigations, various fatigue analyses and calculations, topology optimization, stress and distortion calculations, development of a centering and fixing concept for the insert, and consideration of thermal expansion and shrinkage.

Reasons for manufacturing in die casting:
The one-piece die casting design eliminates complex assembly steps (e.g. welding processes). Various parts/components could be eliminated. Mechanical processing can be carried out in a single clamping operation. The insert molding technique achieves weight reduction with the same or higher component performance. Thus, die casting has turned out to be the optimal and most economical process for us.